JP2001307559A - Wiring material and structure of its connection - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a new electrical wire and a flat cable whose conductive part is made of new material. SOLUTION: A core-wire of the electrical wire and a conductor of the flat cable are constituted with high-conductive resin. Also, at the tip of the core-wire of the electrical wire, a terminal is integrated.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wiring member comprising an electric wire and a flat cable which are suitably used for an automobile.

[0002]

2. Description of the Related Art Conventionally, as shown in FIGS.
The electric wire 1 is made of a stranded wire or a single core wire made of copper
And the core wire 1a is covered with an insulating coating 1b made of an insulating resin. The connection between the electric wires is performed by peeling the insulating coating 1b of the electric wire end to expose the core wire 1a, connecting the core wire by crimping or press-fitting the terminal metal fitting 2, and connecting the terminal metal to the other electric wire terminal with a connector. Often connected by a connection.

In a flat cable 5 shown in FIG. 7, a conductor 5a made of copper foil is cut into a narrow band, and these are arranged in parallel at regular intervals, and both surfaces thereof are laminated with insulating resin films 5b and 5c. ing. When this flat cable 5 is connected to a conductor on a printed board, it is often connected using a connector fixed on the board. When the electric wire 1 shown in FIG. 6 is connected to a conductor of a printed circuit board, it is often connected via a connector mounted on the circuit board.

[0004]

As described above, when connecting an electric wire to another electric wire or another device such as an ECU, a terminal fitting is required, and the connection with the terminal fitting is required. A wire stripping step and a crimping or press-fitting step of the terminal fittings are required, resulting in an increase in the number of parts, an increase in the number of work steps, and an increase in cost.

Further, when a flat cable or an electric wire is connected to a printed circuit board, a connector is required. In this case as well, the number of parts increases, the number of work steps increases, and the cost increases.

Further, when the electric wire or the flat harness is disposed of, the conductor is made of a metal material and the insulating coating material is made of a resin material. .

[0007] The present invention has been made in view of the above problems, and by forming the conductor and the insulating coating from the same material, it is possible to reduce the manufacturing cost of electric wires and flat cables and to eliminate the need for sorting work at the time of disposal, thereby improving recyclability. It is an object of the present invention to reduce the number of necessary parts and reduce the number of work steps when enriching and connecting to other electric parts.

[0008]

In order to solve the above-mentioned problems, the present invention comprises an electric wire in which the outer periphery of a round rod-shaped core wire made of a highly conductive resin is covered with an insulating coating made of an insulating resin. We provide wiring materials.

The terminal of the core wire is projected from the insulating coating portion, and the terminal portion is integrally formed at the end. The terminal portion may be a tab-shaped male terminal portion by flattening the core wire, or may be a circular terminal for earth connection as an annular shape.

When forming a tab at the end of the core wire,
The insulating coating is peeled to expose the core wire, and the core wire is formed into a tab shape by press or heat molding. Alternatively, when forming the core wire with a highly conductive resin, a tab may be formed in advance at the core wire terminal, or a round terminal portion or a female terminal portion may be formed.

As described above, when the terminal portion is provided at the core end of the electric wire, the terminal portion is integrally formed with the core end of the electric wire when the terminal portion is connected to another electric wire or another electric component. It is not necessary to connect the terminal fittings, so that the number of parts can be reduced and the connection work of the terminal fittings can be eliminated.

Further, the present invention provides a wiring member comprising a flat cable in which strip-shaped conductors made of a highly conductive resin are arranged in parallel at predetermined intervals, and insulating films are covered on both sides and laminated. ing.

The highly conductive resin used for the electric wire or the flat harness is made of a thermoplastic resin disclosed in JP-A-10-237331 and JP-A-11-342522 and is made of copper, nickel, iron or the like. It is made of a conductive resin composition in which metal fibers are mixed, a lead-free solder (low-melting solder) and a low-melting alloy such as Cu powder dispersed therein.

The thermoplastic resin to which conductive metal fibers are blended includes propylene, polyethylene, polystyrene, acrylonitrile / butadiene / styrene resin, modified polyphenylene oxide resin, polybutylene terephthalate resin, polyethylene terephthalate resin, polyamide resin, aromatic resin Polyamide resin, polyphenylene sulfide resin, liquid crystal polymer, polyetherimide,
Resins such as polybenzimidazole, polyetheretherketone, and polyethersulfone can be used alone or as a blend, and acrylonitrile-butadiene-styrene resin and polybutylene terephthalate resin are particularly preferably used.

The low melting point alloy to be mixed and dispersed in the thermoplastic resin and bonded in a network is an alloy having a melting point of 100 ° C. or higher, preferably 200 ° C. or higher and melting at the time of injection molding. System, Sn-Ag
-Pb system, Sn-Bi system, Sn-Bi-In system, Bi-
Pb-based, Bi-Sn-based, Sn-Cu-based, Sn-Cu-N
i-P system, Sn-Ag system, Sn-Bi-Pb system, Sn-
In-based materials may be mentioned.

The above-mentioned electric wire having a highly conductive resin as a conductor is formed by molding a core wire with a highly conductive resin in a first injection molding (first color) using a mold, and then pulling out the core wire and applying an insulating resin to an outer periphery thereof. It is manufactured in two steps of coating and forming an insulating coating. Flat cables are also manufactured by molding a highly conductive resin to form a strip-shaped conductor, and pulling out the conductor in parallel while laminating insulating films on both surfaces thereof.

When the above-mentioned electric wire or flat cable is connected to the conductor of the printed circuit board, the core wire of the electric wire or the conductor of the flat cable is placed in a through hole formed so as to communicate with the conductor of the printed circuit board and the substrate. The connection is established by heating and filling the through hole with a highly conductive resin. Therefore, the connector required when connecting the conductor of the printed circuit board and the electric wire or the flat cable can be eliminated. For this reason, the connection parts can be eliminated and the number of work steps required for the connection can be eliminated, so that the cost until the product is completed can be greatly reduced.

Further, when the core of the electric wire or the conductor of the flat cable is molded with a highly conductive resin, the same material as the insulating coating made of the insulating resin is used, so that there is no sorting step at the time of disposal and the recyclability can be improved.

[0019]

Embodiments of the present invention will be described below with reference to the drawings. 1 to 3 show a wiring member made of the electric wire 10 of the first embodiment. The electric wire 10 has a configuration in which a core wire 11 is formed from a highly conductive resin and is covered with an insulating coating portion 12 made of an insulating resin.

FIGS. 2A and 2B show the terminal of the electric wire 10 and the tab 11a of the male terminal portion formed integrally with the core wire 11. FIG. As shown in FIG. 2 (A), the tab 11a is peeled off at the end of the electric wire 10 to expose the core wire 11 and is pressed while heating the exposed core wire 11 so that the core wire 11 is pressed. Is deformed into a flat shape, and FIG.
As shown in (B), a tab 11a serving as a male terminal portion is formed on the core wire 11 protruding from the insulating coating 12. Further, if necessary, a locking hole 11b is formed in a part of the tab 11a by punching. The electric wire 10
When is a fixed size, tabs 1
Alternatively, the core wire 11 may be covered with the insulating coating 12 except for the tabs 11a at both ends.

When the above-mentioned electric wire 10 is connected to another conventional electric wire, the electric wire 10 can be connected to the terminal of the other electric wire, inserted into the female terminal portion and locked. In addition, as shown in FIG. 3A, terminal tabs 11a of a plurality of electric wires 10 can be overlapped and heated and welded to each other to form a terminal concentrated splice. Further, as shown in FIG. 3B, when connecting the printed circuit board 20 and the electric wire 10,
Through hole 20 provided in communication with substrate 20 and conductor 21
The tab 11a of the electric wire 10 is superimposed on the a and 21a, and the tab 11a is melted by heating in this state, so that the through hole 2
0a and 21a are filled and connected as rivets. Furthermore, as shown in FIG. 3 (C), when the round terminal 11c is formed at the tip of the core wire 11 in advance, it is used as an earth terminal and is fixed to the vehicle body 25 by bolts 26.

FIG. 4 shows a flat cable 3 according to a second embodiment.
0 indicates a wiring member. In the flat cable 30, strip-shaped conductors 31 made of a highly conductive resin are arranged in parallel at predetermined intervals, and insulating films 32,
33 and laminated. The ends of the flat cable 30 that are connected to other electrical components also have the insulating films 32 and 33 peeled off to expose the conductor 31. Note that, similarly to the case of the electric wire, the conductor 31 may be formed in advance in a state where the conductor 31 is exposed to the terminal.

When the flat cable 30 is connected to the printed circuit board 20, as shown in FIG. 5, the conductor 31 is provided on through holes 20a, 21a provided in communication with the board 20 and the conductor 21, as shown in FIG. The conductor 31 is melted by heating in this state, and the through holes 20a, 2a
Fill 1a and connect as a rivet. The conductor 21 of one printed circuit board 20 is connected to the core wire 11 of the electric wire 10 of the first embodiment and the flat cable 30 of the second embodiment.
May be connected by the above method.

[0024]

As is apparent from the above description, according to the present invention, a high conductive resin is used in place of the conventional copper as the core of the electric wire and the conductor of the flat cable. By heating the conductor, the conductor can be directly welded and connected to the conductor or the like of the printed circuit board. Therefore, the connector connection conventionally required can be eliminated.

In the case of an electric wire, if the core terminal protruding from the insulating coating portion is formed in advance as a terminal portion such as a tab,
The connection with the terminal fitting becomes unnecessary, and the number of components and the number of connection steps can be reduced.

Both electric wires and flat cables use a highly conductive resin instead of a metal such as copper for the conductive portion, and replace the wiring material conventionally formed of different materials (metal and resin) with the same material (metal and resin). Since the wiring member is made of a highly conductive resin and an insulating resin), a recyclability can be improved without the necessity of a material separation step at the time of disposal.

[Brief description of the drawings]

FIG. 1 is a partially broken perspective view showing an electric wire according to a first embodiment.

FIGS. 2A and 2B are perspective views showing a step of forming a tab on a core wire of the electric wire.

FIGS. 3A, 3B, and 3C are schematic diagrams showing examples of using the electric wire.

FIG. 4 is a perspective view showing a flat cable according to a second embodiment.

FIG. 5 is a cross-sectional view showing a state where the flat cable is connected to a printed circuit board.

FIG. 6A is a perspective view showing a conventional electric wire, and FIG. 6B is a side view showing a state where a terminal is connected to the electric wire.

FIG. 7 is a drawing showing a conventional flat cable.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Electric wire 11 Core wire 11a Tab 12 Insulation coating part 20 Substrate 21 Conductor 30 Flat cable 31 Conductor 32, 33, insulating film

Claims (4)

[Claims] 1. A wiring member comprising an electric wire in which an outer periphery of a round bar-shaped core wire made of a highly conductive resin is covered with an insulating coating layer made of an insulating resin. 2. The wiring member according to claim 1, wherein a terminal of the core wire protrudes from the insulating coating layer, and a terminal portion is integrally formed with the protruding portion. 3. A wiring member comprising a flat cable in which strip-shaped conductors made of a highly conductive resin are arranged in parallel at a predetermined interval, and laminated with an insulating film covering both sides. 4. The core wire or conductor of the wiring member according to any one of claims 1 to 3 is welded to a through hole formed in the printed circuit board and connected to the conductor of the printed circuit board. Wiring material connection structure.